Sr. NPI Engineer: High-Speed LPBF & Digital Workflows

VulcanForms; Harvard (MA); On-site; USD 106,000 - 171,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

Life insurance

Paid time off

401(k) with company match

Job summary

VulcanForms, a leader in laser powder bed fusion, is seeking a Sr. NPI Product Development Engineer to architect and optimize high-speed LPBF processes and digital workflows for scalable production.

You will influence roadmaps across hardware, software, materials, and operations, delivering production-ready parts for strategic customers, mentoring engineers, and driving CAPA through data analytics.

Qualifications

• 3+ years of progressive, hands-on experience in product or applications development, with a documented track record of scaling LPBF or directed energy deposition (DED) processes into high-volume manufacturing environments.
• Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a related field; Master’s or Ph.D. is highly preferred.
• Expert-level proficiency in advanced 3D CAD software (e.g., Siemens NX, Creo, SolidWorks) along with specialized build-preparation tools (e.g., Magics, nTopology, Amphyon).
• Deep mastery of GD&T, advanced statistical process capability, tolerance stack-up analysis, and complex DFM/DfAM constraints.
• Outstanding leadership and communication skills, with a proven ability to influence technical roadmaps, align multidisciplinary stakeholders, and mentor engineering talent.
• Strong working knowledge of subtractive manufacturing operations (5-axis milling, turning, EDM) and their integration with additive workflows.

Responsibilities

• Architect, govern, and scale integrated LPBF process workflows from initial R&D through high-volume serial production, systematically elevating Manufacturing Readiness Levels (MRL) across the organization.
• Lead the development, standardization, and optimization of core LPBF process recipes and complex build configurations; define the platform standards that ensure repeatability and traceability across the VulcanForms fleet.
• Synthesize highly complex customer and market requirements into foundational engineering specifications; champion top-down Design for Additive Manufacturing (DfAM) methodologies that maximize geometric freedom while balancing supports, tolerances, and metallurgical performance.
• Oversee the technical execution of First Article Inspections (FAI) and critical production launches for high-stakes industries, including aerospace, defense, medical, and semiconductor.
• Serve as the definitive technical subject matter expert (SME) for tier-one customers, program management, and executive leaders—driving alignment on production roadmaps, steering technical reviews, and resolving high-priority engineering challenges.
• Own systemic root cause investigations for complex print defects, implementing org-wide corrective and preventive actions (CAPA) through advanced data analytics and iterative testing.
• Drive cross-functional collaboration with downstream automation, machining, and finishing process owners to embed comprehensive Design for Manufacturing (DFM) principles from day one.
• Mentor and coach junior and mid-level engineers, fostering a culture of technical excellence; establish standard operating procedures (SOPs), quality control standards, and change management logs to ensure strict production compliance.

Skills

LPBF experience

3D CAD software

GD&T

DfAM principles

Leadership

Communication

Education

Bachelor's degree

MS or PhD preferred

Tools

Magics

nTopology

Amphyon

Job description

VulcanForms, a leader in laser powder bed fusion, is seeking a Sr. NPI Product Development Engineer to architect and optimize high-speed LPBF processes and digital workflows for scalable production.

You will influence roadmaps across hardware, software, materials, and operations, delivering production-ready parts for strategic customers, mentoring engineers, and driving CAPA through data analytics.